Capabilities

DyCast Specialties Corporation is a full-service die-casting company that produces precision aluminum and zinc castings. We provide a comprehensive range of engineering services, including design ideas, prototypes, tooling, and production, as well as metal machining and finish. We can deliver the highest quality and service to our clients because of our skilled team.

High-Pressure Die Casting

High-pressure die casting is a process in which it forces molten metal into a mold cavity under high pressure. The high pressure used in this process allows for a much more detailed and accurate final product.

According to Engineering.com, it is applicable for large-scale production and used for metals with high melting points, such as aluminum, brass, and cast iron.

The high-pressure die casting process begins with melting the metal in a furnace and then injected into the mold cavity under high pressure. The metal cools and solidifies in the mold, then ejects the part. The high pressure in this process ensures that the metal retains its shape and produces a robust and durable component.

Some advantages of high-pressure die casting include:

The process produces parts with tight tolerances and smooth surfaces
It is a fast and efficient way to produce large quantities of parts
The process is adaptable to automation, which reduces labor costs
High-pressure die casting is well suited for creating complex shapes
Using the process with various metals, including aluminum, brass, and cast iron.

Aluminum Castings

Aluminum castings are a versatile and essential manufacturing component for many industries. Our facility specializes in aluminum die castings, which create complex geometric shapes.

We offer small, medium, and large die castings, with parts weighing up to 10 pounds. Our machine sizes range from 600 to 725 tons.

We specialize in several different aluminum alloys, such as:

In addition, we have to die-cast machine cells dedicated to high-pressure aluminum die casting. These cells consist of 600 – 725 ton die casting machines, and 600LB/hour 4800LB capacity furnaces, and maintain tight tolerances of +/- 0.0025. Mold longevity can range anywhere from 40,000 shots to 100,000 shots depending on part and mold design complexities.

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Zinc Castings

When it comes to creating complex yet durable metal parts, zinc castings are in a league of their own. ThoughtCo states that various products have zinc alloys, such as corrosion-resistant marine components and musical instruments. Able to reproduce even the most intricate shapes, zinc castings are applicable for small to medium-sized parts.

And thanks to die-cast cells that use high-pressure zinc alloy, these parts are also solid and resistant to wear and tear. Plus, with mold longevity of up to 1,500,000 shots, you can be sure that your zinc castings will be around for the long haul.

We specialize in several different zinc alloys, such as:

Zamak 3
Zamak 5
Hybrid ZA-8
Hybrid ZA-27

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Tooling Construction

The quality of your tools has a direct impact on the quality of your work. That’s why DyCast Specialties only uses the best materials and construction methods for their tooling, molds, and dies.

Premium H-13 tool steel is applicable for all molds, heat treated to 46-48 R/C for durability and longevity. The in-house tooling department, and outsourced vendors, produce top-quality results that meet or exceed customer expectations.

Tooling Concept and Equipment List

DyCast Specialties uses state-of-the-art software and equipment to create tools that meet the highest standards.

Our tooling concepts are as follows:

10″ x 12″ Standard DME Unit Dies
12″ x 15″ Standard DME Unit Dies
12″ x 15″ HD DME Unit Dies
15″ x 18″ Standard DME Unit Dies
15″ x 18″ HD DME Unit Dies
8″ x 8″ House Inserts
Standard Cavity Retainer Sets

The following is a list of our equipment:

8 – 06 ton Trim Press
3 – 08 ton Trim Press
2 – 10 ton Trim Press
2 – 12 ton Trim Press
1 – 20 ton Trim Press
1 – 30 ton Trim Press
1 – 35 ton Trim Press

CNC Machining Capabilities

DyCast Specialties offers a wide range of CNC machining capabilities to create your needed parts.

We use state-of-the-art software and equipment, including:

Our facility has three CNC Vertical Milling machines, each capable of producing high-quality parts and components.
Our machining center is located in-house and has a tolerance level of +/- 0.00025 inches.

Finishing and Deburring

DyCast Specialties offers various finishing and deburring services to create the perfect product for your needs.

We offer three types of vibratory finishing:

Vibratory finishing: Removes burrs, sharp edges, and other imperfections from metal parts and components, smoothing out the part surface making it ideal for cosmetic applications and best used on small, medium, and large castings.
Tumbler finishing: This method uses a rotating drum to smooth and polish the surface of metal parts. It works excellent for deburring small casting components.
Cryogenic Deburring: This process uses liquid nitrogen to remove flash from metal parts. Castings that are small to medium work best with this method.

DyCast Specialties also offers various coating and plating options to protect your parts from corrosion and other environmental factors.

Additional Processes

DyCast Specialties helps you create the perfect product by customizing it to your needs and preferences.

What We offer:

Annealing

This process relieves internal stresses in metals caused by heat treatment, welding, or machining. It makes the metal more ductile and less brittle and improves its machinability.

Shot Bead Blasting

This process uses steel shot to remove surface impurities and create a smooth, even finish. The advantages of shot bead blasting include a clean surface, improved adhesion, and increased corrosion resistance.

Chromate Conversion

Adding multiple coats and cleanings creates a thin, protective layer on the surface of the aluminum and other metals. It improves corrosion resistance and durability.

Clear Anodizing

This process creates a protective layer on the surface of aluminum parts. It is ideal for applications where the cosmetic appeal is essential. Clear anodizing provides advantages such as many color choices, extended service life, and improved corrosion protection.

E-Coating

This method gives a protective covering to metal components widely used in the automobile and appliance industries. E-coating offers advantages such as increased corrosion protection, improved durability, and a wide range of color choices.

Black Zinc Chromate

This plating process gives a black finish to metal parts often used for cosmetic purposes.

Bright Zinc Chromate

This plating process gives a bright, shiny finish to metal parts also used for cosmetic purposes.

Yellow Zinc Chromate

The plating process gives metal parts a yellow finish.

Liquid Paint

This process gives a smooth, even finish to metal parts. It is available in a wide range of colors.

Pad Printing

This process allows for transferring complex designs and patterns onto metal surfaces.

Powder Coat Paint

This technique leaves metal components with a smooth, uniform appearance. There are a variety of colors to choose from.

X-Ray

We offer in-house X-Ray capabilities to ensure the quality of your product.

Assembly

We offer various assembly services to put your product together.

We're the best because we put you first

DyCast Specialties offers a wide range of capabilities to meet your needs. We have a team of experts who can assist you in designing and developing your product.

We always put you first and work tirelessly to ensure you get the best possible outcome without sacrificing quality or service. Don’t hesitate to contact us or request a quote if you’re interested in our services. We would be more than happy to help you achieve your goals.

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